Stator Cooling Assembly With Sealed End Winding Chambers
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Solution Overview
Problem
Existing electric motor designs face challenges in thermal management, particularly with immersion cooling of stators, which can lead to fluid leakage and manufacturing inefficiencies, complicating serviceability and reducing customer appeal.
Innovation Solution
An electric machine design featuring a sleeve and housing assembly with a fluid inlet and end winding chambers that implement immersion cooling with reduced leakage risk, utilizing a press-fit interface and sealing components to efficiently cool the stator while allowing for easier manufacturing and service.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If immersion cooling is implemented in the stator, then motor efficiency is improved, but fluid leakage risk increases and manufacturing complexity increases
Solution Approach 1:
The stator is divided into separate modular components (stator core, end windings, housing) that can be assembled and sealed independently. The housing is split into multiple sections that can be separately manufactured and then joined with sealing components, allowing for better control of fluid containment in each segment rather than requiring a single complex sealed structure.
Solution Approach 2:
Sealing components are introduced as intermediary elements between the stator components and the cooling fluid. These sealing components act as mediators that prevent direct contact between the cooling fluid and potential leakage paths, while still allowing the immersion cooling to function effectively.
2Loss of energy
If immersion cooling is implemented in the stator, then motor efficiency is improved, but device complexity increases
Solution Approach 1:
The stator cooling assembly is segmented into modular components that can be manufactured separately using standard processes and then assembled. This segmentation allows each component to be optimized for its specific manufacturing requirements while simplifying the overall production process compared to manufacturing a single complex integrated structure.
Solution Approach 2:
The housing and sealing components are designed to perform multiple functions: structural support, fluid containment, and thermal management. By making these components multi-functional, the number of separate parts is reduced, simplifying the overall device structure while maintaining effective immersion cooling.
3Ease of manufacture
If traditional stator sealing is used, then manufacturing is simpler, but serviceability is reduced
Solution Approach 1:
The stator assembly is segmented into removable modules (end windings, housing sections, sealing components) that can be independently accessed and serviced. This modular segmentation maintains manufacturing simplicity while enabling easy disassembly for maintenance and repair operations.
Solution Approach 2:
The sealing system is designed with dynamic characteristics that allow for controlled disassembly and reassembly. The sealing components can be engaged and disengaged in a controlled manner, enabling service operations without compromising the seal integrity when reassembled, thus improving serviceability while maintaining manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively increases motor efficiency by reducing fluid leakage and simplifying manufacturing and service processes, enhancing customer appeal through improved thermal management and robust component usage.
Implementation Method 1
The first end winding chamber is in direct fluidic communication with the cooling channels, allowing heat to transfer from the stator end windings to the cooling fluid
Implementation Method 2
The cooling assembly circulates cooling fluid through the end winding chambers and cooling channels to remove heat from the stator
Data Source
AI summary
Methods and systems for an electric machine. The electric machine includes, in one example, a sleeve that encloses a stator and a rotor, a housing removably coupled to the sleeve and circumferentially enclosing a portion of the sleeve. The electric machine further includes a fluid inlet that extends through at least one of the sleeve and the housing and is in fluidic communication with a stator cooling assembly.